Retaining wall block

ABSTRACT

A retaining wall block having a rear flange and a mold box and method of making the block. The mold box is configured with a mold cavity that includes a vertical flange forming cavity extending from the top of the mold box to the bottom of the mold box.

This application is a continuation of U.S. Ser. No. 12/252,837, filedOct. 16, 2008, which claims the benefit of U.S. Provisional ApplicationNo. 60/980,886, filed Oct. 18, 2007, entitled “Retaining Wall Block”,the contents of each of which are hereby incorporated by referenceherein.

FIELD OF THE INVENTION

The present invention relates generally to retaining wall blocks andretaining walls constructed from such blocks. Additionally, theinvention includes block molds and methods of manufacturing the blocks.

BACKGROUND OF THE INVENTION

Retaining walls are used in various landscaping projects and areavailable in a wide variety of styles. Numerous methods and materialsexist for the construction of retaining walls. Such methods include theuse of natural stone, poured concrete, precast panels, masonry, andlandscape timbers or railroad ties. In recent years, segmental concreteretaining wall units, which are dry stacked (i.e. built without the useof mortar), have become widely accepted in the construction of retainingwalls. An example of such a unit is described in U.S. Pat. No. RE34,314, which is issued to Forsberg (Forsberg '314). Such retaining wallunits have gained popularity because they are mass produced andconsequently, relatively inexpensive. They are structurally sound, easyand relatively inexpensive to install, and couple the durability ofconcrete with the attractiveness of various architectural finishes.

Typically, retaining walls are constructed with multiple courses ofblocks. The various courses may be tied together or connected in somemanner. For example, numerous block designs have used a sheer connectorembodied in the blocks shape to align the blocks with a setback, orbatter. A common form of such sheer connectors is a rear, downwardlyprojecting lip or flange. In forming a multi-course wall, the blocks areplaced such that the flanges contact the upper back edge of the blockslocated in the course below. As such, blocks having flanges are causedto become aligned with the blocks position below, while at the same timeproviding a degree of resistance against displacement of individualblocks by earth pressures. In walls formed using blocks of this type,the rear flanges of the blocks cause the wall to have a setback fromcourse to course such that the wall slopes backward at an angle which ispredetermined by the width of the flanges.

Retaining walls using blocks having a rear flange are well known in theart. For example, U.S. Pat. No. 3,323,363 (Schmitt) describes an earlyuse of a retaining wall block with a rear flange. More recently, U.S.Pat. No. 5,294,216 (Sievert) describes a retaining wall constructed withretaining wall blocks having rear flanges. The Sievert patent alsodescribes a mold and a method of making the retaining wall blocks in themold. Specifically, Sievert discloses a mold and method whereby twoblocks which are split later are simultaneously formed in facing pairsin the mold. The bottom surface of the blocks is formed at the top ofthe mold cavity and the flanges of the blocks are formed at the top ofthe mold by a compression head which has an instep which is shaped toform the flange of each block. There are several disadvantages with thisprocess of forming retaining wall blocks. First, since mold boxes andproduction pallets come in typical sizes the orientation of the blockswith their top surfaces on the production pallets takes up considerablespace and limits the number of blocks which can be formed on a palletduring a production cycle. Further, since the blocks are formed in pairsand are split apart along their front faces after the blocks have beencured the only texture which is imparted to the front faces of theblocks is the roughness which results from the splitting process.

Another method of forming a retaining wall block having a rear lip isdescribed in U.S. Pat. No. 5,598,679 (Orton). Orton discloses a castconcrete block which is formed on its side. The cast concrete block isformed with at least two vertically oriented splitting grooves to enableit to be split into at least three construction blocks after it has beenremoved from the mold. Since the blocks are split along the front facesof the blocks the only texture which is imparted to the front faces ofthe blocks is the roughness which results from the splitting process.

Even more recently another method of forming a retaining wall blockhaving a rear flange is described in U.S. Pat. No. 7,140,867 (Scherer).Scherer discloses a mold having a mold cavity wherein the rear surfaceof a block is formed adjacent a pallet which closes the bottom of themold and a front face of the block is formed at the top of the moldcavity. This permits the front face of the block to be impressed with apattern formed into the surface of a stripper shoe which is used tocompress the moldable block material in the mold cavity. In this moldthe rear flange of the block is formed in a flange-forming sub cavitywhich is defined between an undercut in one of the side walls of themold and a portion of the flat surface of the pallet. Since theretaining wall blocks are oriented with their rear faces on theproduction pallet they take up less room and thus allow a greater numberof retaining wall blocks to be produced on each pallet. Further, sincethe front faces of the blocks are oriented at the top of the mold box adesired texture or pattern can be imprinted on the front face with thestripper shoe. However, this mold box has several disadvantages. First,since the side surfaces of the retaining wall block which is formedconverge towards the rear of the block the opposing side walls of themold between which the converging sides of the block are formed arerequired to pivot or retract so that the bottom of the mold cavity opensto allow the retaining wall block to be discharged from the mold cavity.These moving side walls may become plugged with the moldable material orotherwise malfunction causing the mold to work improperly. Second,during the block manufacturing process if the flange-forming sub cavityis not completely filled with material or properly cleaned between moldcycles the flange may not be properly or completely formed on the block.Third, the orientation of the front face of the block at the open top ofthe mold box prohibits the blocks formed in the mold from being providedwith a core. Blocks having cores are lighter and easier to handle andinstall than blocks without cores and are less costly to build.

SUMMARY OF THE INVENTION

The present invention provides an improved retaining wall block having atextured front face and a rear flange extending from the rear surface ofthe block. In some embodiments the block includes a core or a pluralityof cores extending between first and second side surfaces of the block.The core or cores may have any desired shape including round, oval,rectangular and square. The invention includes the mold in which theretaining wall block is formed and the method for making the retainingwall block in the mold. The invention also includes a retaining wallmade with the block and the method of constructing the retaining wallwith the blocks.

In one embodiment the invention is a retaining wall block for use inmaking a retaining wall. The block comprises opposed front and rearfaces, opposed and substantially parallel top and bottom surfaces,opposed first and second side surfaces, the first side surface beingorthogonal to the front and rear faces, the second side surfaceconverging inwardly from the front to the rear face. The block includesa flange extending from the rear face of the block downward past thebottom surface of the block, the flange being configured such that theflanges of blocks in a first course of the retaining wall overlap thetop surfaces of blocks in an adjacent lower course of the retaining wallto thereby provide a connection between the courses of blocks andsetback between the courses of blocks in the retaining wall. The blockmay include a core extending between the first and second side surfaces,the core being substantially parallel to the front and rear faces. Thefront face may be imparted with a three dimensional surface texture orpattern and the core may comprise a plurality of cores. The core mayhave a shape selected from round, oval, rectangular, and square. Thesecond side surface of the block may form an angle α with respect to thefront face and wherein angle α is between about 5° to 20°, or whereinangle α is between about 7½° to 15°. Further, the retaining wall blockmight comprise a channel formed into a rear portion of the top surfaceand an upper portion of the rear face, the channel extending from thefirst side surface to the second side surface.

In another embodiment the invention is a mold assembly for use inproducing retaining wall blocks having some or all of the featuresdescribed above. The mold assembly may comprise a horizontal planarbottom member, a compression head, a mold box having a plurality of sidewalls that define a plurality of mold cavities having open mold cavitytops and open mold cavity bottoms, the horizontal planar memberenclosing the open mold cavity bottoms of the plurality of mold cavitiesand the compression head enclosing the open mold cavity tops of theplurality of mold cavities during a block forming process. Each of theplurality of mold cavities may be shaped to form a single retaining wallblock. Each of the plurality of mold cavities may be oriented such thatthe first side surface is formed at the bottom of the mold cavity andthe second side surface is formed at the top of the mold cavity. One ofthe side walls of each of the plurality of mold cavities may be moveablefrom an inward block forming position to a retracted discharge position,the moveable sidewall having a three dimensional surface texture orpattern that imparts to the front face of the retaining wall block thethree dimensional surface texture or pattern during the block formingprocess. The sidewalls of each of the plurality of mold cavities areshaped to form a vertically extending flange forming channel thatprovides the retaining wall block with a flange extending from the rearface downward past the bottom surface of the retaining wall block. Themold assembly further includes a core forming member which extendsvertically into at least one of the plurality of mold cavities toprovide the retaining wall block formed therein with a core extendingfrom the first side surface to the second side surface. The core formingmember may be configured to form a plurality of cores extending from thefirst side surface to the second side surface of the retaining wallblock and the core or cores may have a shape selected from round, oval,rectangular and square. The compression head includes a lower surfacewhich encloses the open mold cavity tops. The lower surface may beangled at an angle α with respect to horizontal such that the secondside surface of the retaining wall block formed in each of the pluralityof mold cavities during the block forming process forms angle α withrespect to the front face of the retaining wall block, and wherein angleα is between about 5° to 20°, or between about 7½° to 15°. Further, thesidewalls of each of the plurality of mold cavities may be shaped toform a vertically extending ridge that provides the retaining wall blockwith a flange receiving channel formed into a rear portion of the topsurface and an upper portion of the rear face of the retaining wallblock.

In another embodiment the invention is a mold assembly for use inproducing retaining wall blocks. The mold assembly may comprise ahorizontal planar bottom member, a compression head, and a mold boxhaving a plurality of side walls that define a plurality of moldcavities having open mold cavity tops and open mold cavity bottoms. Thehorizontal planar member encloses the open mold cavity bottoms of theplurality of mold cavities and the compression head encloses the openmold cavity tops of the plurality of mold cavities during a blockforming process. Each of the plurality of mold cavities are shaped toform a single retaining wall block having features as described herein.Each of the plurality of mold cavities may be oriented such that thefirst side surface is formed at the bottom of the mold cavity and thesecond side surface is formed at the top of the mold cavity. One of theside walls of each of the plurality of mold cavities may be moveablefrom an inward block forming position to a retracted discharge positionand the moveable sidewall may have a three dimensional surface textureor pattern that imparts to the front face of the retaining wall blockthe three dimensional surface texture or pattern during the blockforming process. The sidewalls of each of the plurality of mold cavitiesare shaped to form a vertically extending flange forming channel thatprovides the retaining wall block with a flange extending from the rearface downward past the bottom surface of the retaining wall block. Thecompression head has a lower horizontal surface which encloses the openmold cavity top of at least one mold cavity. The lower surface may havea three dimensional surface texture or pattern that imparts to thesecond sidewall of the retaining wall block the three dimensionalsurface texture or pattern during the block forming process. Further,the sidewalls of each of the plurality of mold cavities may be shaped toform a vertically extending ridge that provides the retaining wall blockwith a flange receiving channel formed into a rear portion of the topsurface and an upper portion of the rear face of the retaining wallblock.

In a further embodiment the invention is a mold assembly for use inproducing retaining wall blocks of a first type and retaining wallblocks of a second type. The assembly comprises a horizontal planarbottom member, a compression head, and a mold box having a plurality ofside walls that define a plurality of mold cavities having open moldcavity tops and open mold cavity bottoms. At least one of the pluralityof mold cavities may be configured to form the first type block and theremainder of the mold cavities may be configured to form the second typeblock. The horizontal planar member encloses the open mold cavitybottoms of the plurality of mold cavities and the compression head hasone or more horizontal surfaces for enclosing the open mold cavity topof the at least one mold cavity configured to form the first type blockand the compression head having one or more angled surfaces forenclosing the open mold cavity tops of the remainder of the plurality ofmold cavities used to form the second type block during a block formingprocess. Each of the plurality of mold cavities is shaped to form asingle retaining wall block having features similar to those describedabove. Each of the plurality of mold cavities may be oriented such thatthe first side surface is formed at the bottom of the mold cavity andthe second side surface is formed at the top of the mold cavity. One ofthe side walls of each of the plurality of mold cavities may be moveablefrom an inward block forming position to a retracted discharge position.The moveable sidewall has a three dimensional surface texture or patternthat imparts to the front face of both types of the retaining wall blockthe three dimensional surface texture or pattern during the blockforming process. The sidewalls of each of the plurality of mold cavitiesare shaped to form a vertically extending flange forming channel thatprovides the retaining wall block with a flange extending from the rearface downward past the bottom surface of the retaining wall block. Theassembly may further include a core forming member which extendsvertically into each of the remainder of the plurality of mold cavitiesused to form the second type block to provide the second type blockformed therein with a core extending from the first side surface to thesecond side surface. The horizontal surface of the compression head mayhave a three dimensional texture or pattern which imparts to the secondside surface of the first type of block the three dimensional texture orpattern during the block forming process.

In another embodiment the invention is a method of making a plurality ofretaining wall blocks comprising providing a mold assembly including apallet, a compression head, a mold box having a plurality of side wallsthat define a plurality of mold cavities having open mold cavity topsand open mold cavity bottoms, and a core forming member that extendsvertically into at least one of the plurality of mold cavities from themold cavity top to the mold cavity bottom. Each of the plurality of moldcavities are shaped to form a single retaining wall block having thefeature as described herein. Each of the plurality of mold cavities maybe oriented such that the first side surface is formed at the bottom ofthe mold cavity and the second side surface is formed at the top of themold cavity. The sidewalls of each of the plurality of mold cavities areshaped to form a vertically extending flange forming channel. One of theside walls of each of the plurality of mold cavities may be moveablefrom an inward block forming position to a retracted discharge position,the moveable side walls having a three dimensional surface texture orpattern. The method includes positioning the pallet beneath the mold boxto enclose the mold cavity bottoms; filling the mold cavities with drycast concrete while the moveable side walls are in the inward blockforming position; lowering the compression head to enclose the open moldcavity tops and compress the dry cast concrete within the plurality ofmold cavities; moving the moveable side walls from the inward blockforming position to the retracted discharge position; and lowering thepallet and the compression head to strip the dry cast concrete from theplurality of mold cavities. The core forming member may be configured toform a plurality of cores extending from the first side surface to thesecond side surface of the retaining wall block. Further, the coreforming member may be configured to form a core having a shape selectedfrom round, oval, rectangular and square. The compression head includesa lower surface which encloses the open mold cavity tops. The lowersurface may be angled at an angle α with respect to horizontal such thatthe second side surface of the retaining wall block formed in each ofthe plurality of mold cavities during the block forming process formsangle α with respect to the front face of the retaining wall block, andwherein angle α is between about 5° to 20°, or between about 7½° to 15°.The side walls of each of the plurality of mold cavities may be shapedto form a vertically extending ridge that provides the retaining wallblock with a flange receiving channel formed into a rear portion of thetop surface and an upper portion of the rear face of the retaining wallblock.

In a further embodiment the invention is a retaining wall comprising aplurality of courses of retaining wall blocks having the featuresdescribed above. The retaining wall includes a first upper course and asecond lower course of blocks. The blocks in the first upper course arepositioned over adjacent blocks in the second lower course such that theflanges of the blocks in the first course extend downward behind the topsurface of blocks in the second course to engage the rear face of blocksin the first course and to provide a setback from the second course tothe first course equal to a depth of the flanges and such that the coresof the blocks in each course align horizontally, the cores being sizedto accept a horizontal reinforcement member.

In another embodiment the invention is a method of constructing aretaining wall using the blocks described above. The wall thus built mayinclude blocks of the first type and/or blocks of the second type.

In another embodiment the invention is a method of stacking blocks withthe features described above on a shipping pallet. The blocks arestacked on the pallet in multiple layers in the same orientation theyare when removed from the mold. In this orientation the layer of blockson the shipping pallet is formed with an angled side of the blocksfacing up to create an upper surface layer that is not level. The methodincludes placing a wedge or triangular shaped insert over the first andsucceeding layers of blocks in order to form a flat surface on whicheach succeeding layer of blocks may be placed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of the retaining wallblock in accordance with the invention.

FIG. 2 is another perspective view of the block of FIG. 1 oriented onone of its side surfaces in a position similar to the position in whichthe block is formed in the mold.

FIG. 3A is a plan view of an embodiment of the mold box in accordancewith the present invention. FIG. 3B is a plan view of an alternateembodiment of the mold box in accordance with the present invention.

FIG. 4A is an end view of the retaining wall blocks formed in the moldof FIG. 3A sitting on a pallet after removal from the mold. FIG. 4B isan end view of a compression head of a stripper shoe for use with thepresent invention. FIG. 4C is an end view of a core bar for use with thepresent invention.

FIG. 5A is another embodiment of a mold box in accordance with thepresent invention. FIG. 5B is another alternate embodiment of a mold boxin accordance with the present invention.

FIG. 6 is an end view of retaining wall blocks formed in the mold box ofFIG. 5A sitting on the pallet after they have been removed from the moldbox.

FIG. 7 shows retaining wall blocks of the present invention stacked on ashipping pallet.

FIG. 8 shows a portion of a concave wall formed with retaining wallblocks of the present invention.

FIG. 9 shows a portion of a convex wall formed with retaining wallblocks of the present invention.

FIG. 10 is a retaining wall having both straight and curved portionsformed with retaining wall blocks of the present invention.

FIG. 11 is a partial cross-sectional side view of a retaining wallformed with retaining wall blocks of a further embodiment of the presentinvention and illustrating various options for forming cores in theblocks.

FIG. 12 is a perspective view of a portion of a retaining wall formedwith blocks of the present invention including a rectangular cornerblock having a textured surface formed on both the front face of theblock and one of the adjacent side walls.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

A retaining wall block 10 according to the present invention is shown inperspective in FIGS. 1 and 2. Block 10 comprises a block body defined byopposed front and rear faces 12 and 14, respectively. The front and rearfaces are substantially parallel and are separated by a distance Z whichcomprises the depth of the block. The depth of the block is determinedby the size of the mold in which the block is formed as will bedescribed in more detail hereafter. Typically, the depth will be in therange of about 5 to 9 inches. The block body includes opposed top andbottom surfaces 16 and 18, respectively. The top and bottom surfaces aresubstantially parallel and separated by a distance Y which comprises thethickness or height of the block. The block thickness is determined bythe size of the mold and for a typical block may be 4 inches. The blockbody includes opposed first and second side surfaces 20 and 22,respectively. The first and second side surfaces are not parallel toeach other. Rather, first side surface 20 is orthogonal to both thefront and rear faces of the block. Second side surface 22 is angled toconverge inwardly from the front face of the block to the rear face.Although the first side surface 20 is shown on the left side of theblock 10 of FIG. 1 it should be understood that the side surfaces couldbe switched so that the angled side was on the left and the orthogonalside on the right. Second side surface 22 forms an angle alpha (α) withrespect to the front surface of the block as seen in FIGS. 2 and 4.Preferably, angle α is in the range of about 5 to 20 degrees. Morepreferably, angle α is in the range of about 7½° to 15 degrees. Thedistance between the first and second side surfaces at the front face 12of the block defines the width X of the block. The width of the blockdepends upon the size of the mold in which the block is formed and maybe, for example, 8 inches or 12 inches.

Block 10 includes a flange 24 extending from the rear face 14 downwardpast the bottom surface 18 of the block. The flange has a front surface26, a lower surface 28 and a back surface 30 that extends continuouslyfrom the rear face 14 of the block. The purpose of the rear flange is toprovide both a desired amount of setback between courses of blocks in aretaining wall and a means of securing one course of blocks above alower course of blocks in a retaining wall to help prevent blockdisplacement due to pressures from the earth or backfill behind thewall. As such, the size of the flange may be selected to accomplishthese desired objectives. For example, the back surface 30 of the flangemay extend ½ inch below the bottom surface 18 of the block, the lowersurface 28 of the flange may have a depth of approximately ½ inch andthe front surface 26 of the flange may be parallel to the back surface30 or may be angled such that a distance between the lower surface 28and the bottom surface 18 of the block is approximately ¾ inch.

In some embodiments of the invention the block body may also be providedwith a core 32. Core 32 may be of a desired cross-sectional shape whichmay include round, oval, rectangular and square and may comprise one ormore voids or cavities in the block as described in more detail inconnection with FIG. 11.

In accordance with the present invention retaining wall blocks 10 areformed in mold boxes described in FIGS. 3A and 5A having multiple moldcavities and where the blocks are formed with the first side surface 20resting on the production pallet and the second side surface 22 orientedat the top of the open mold cavity. This orientation of the blocks takesup less space on the production pallet than if the blocks were orientedin a mold with their top surface on the production pallet such as in theSievert '216 patent. Thus, the number of mold cavities in the mold boxcan be increased so that a greater number of blocks can be made in aproduction cycle on a production pallet.

FIG. 3A is a plan view of a mold box 50. Mold box 50 includes ten moldcavities 52 in which eight retaining wall blocks 10 and two cornerblocks 72 may be formed in a production cycle on a production pallet asdescribed in more detail hereafter. FIG. 4A is an end view of blocks 10resting on a production pallet 54 after the blocks have been dischargedfrom mold box 50. Blocks of different sizes can be made in mold box 50.By way of example, the blocks formed in mold box 50 may have a width of8 or 12 inches depending on the height of the mold cavities above theproduction pallet, a height of 4 inches, and a depth of 7 inches. Moldbox 50 is configured and sized for use with a typical production palletwhich may have a size of 18 inches by 26 inches.

Mold box 50 generally includes opposing first and second side framewalls 56 and 58 and opposing first and second end frame walls 60 and 62.The mold cavities 52 are formed by division liners 64 and end liners 66which are fixedly or removably attached to frame walls 56, 58, 60 and 62of the mold box in known manner. The liners 64 and 66 form side wallswhich, along with moveable liner 70 described hereafter, define aplurality of mold cavities having open mold cavity tops and open moldcavity bottoms. Each of the mold cavities have a vertical flange formingchannel 34 formed by the side walls extending from the top of the moldbox to the bottom and which form a flange 24 on each block. Blocks 10may be formed with cores. The optional cores are formed with core barswhich span the side frame walls and are used to support core forms whichcreate vertical voids in the blocks produced in the mold cavities. Thisis done in accordance with known techniques and an end view of a corebar and core forms for forming two cores in each block is shown in FIG.4C. It will be understood that this core by is shown by way of exampleand that other core bars with different core form shapes andarrangements may be used as desired. The core forms may be slightlytapered inwardly from the top of the mold to the bottom to insure thatthe blocks may be discharged from the mold cavity without difficulty atthe end of the production cycle.

Mold box 50 also includes moveable side liner mechanisms 68 which areattached to impression face liners 70. During the block production cyclethe movable side liner mechanisms are positioned in a first inward orblock forming position when the mold cavities are filled with moldablematerial. The impression face liners 70 may be created with any desiredthree dimensional texture or pattern and impart to the front face 12 ofthe retaining wall blocks any desired three dimensional texture orpattern when in this first position. When the blocks have been formedand are ready to be discharged from the mold cavities moveable sideliner mechanisms 68 are moved to a second retracted or dischargeposition shown generally on the right side of FIG. 3A. The moveable sideliner mechanisms may comprise rod and piston type mechanisms, worm gearmechanisms, hinged or pivoting walls or any other arrangement known tothose of skill in the art to cause the face impression liners 70 to movebetween the first and second positions. In this retracted position theimpression face liners are spaced from the front face of the blocks farenough to allow the blocks to be discharged from the mold cavitieswithout interference from the face liners. FIG. 3B shows an alternateembodiment of the mold box of FIG. 3A which does not include moveableside liner mechanisms. It should be understood that the mold box is notlimiting and variations and alternate embodiments may be used asdesired. It should be further understood that a plurality, but not all,of the mold cavities may have moveable side liner mechanisms. Forexample, the mold cavities on one side of mold boxes 50 or 100 may havemoveable liner mechanisms and the mold cavities on the other side mayhave stationary side walls.

A stripper shoe compression head such as shown in end view in FIG. 4B isused to compact the material in the mold cavities and to aid indischarging the blocks from the mold cavities when the production cycleis complete. Typically, a lower surface of the compression head whichcontacts the block at the top of the open mold cavity lies in agenerally horizontal plane. This lower surface is typicallydiscontinuous and shaped so that it can be extended into the moldcavities and avoid core bars and core forming elements and the like. Thelower surface of the compression head may have a three dimensionaltexture or pattern to impart such three dimensional texture or patternto the portion of the block at the open top of the mold cavity. Inaccordance with the present invention the surface of the compressionhead which contacts the second side surface of the retaining wall blockat the top of the open mold cavity may be either horizontal to create afirst type block which may be a generally rectangular corner block 72 asshown and described in connection with FIG. 12 or may be angled tocreate a second type block, the angled surface imparting to the secondside surface the angle α as shown in FIGS. 2 and 4. As shown in the twomold cavities in the upper left corner of FIG. 3A the surface of thecompression head which contacts the moldable material at the open top ofthe mold cavity forming the second side surface of the block may betextured or patterned to impart on the second side surface any desiredthree dimensional texture or pattern. This is especially useful informing a rectangular corner block where both the front face and anadjacent side are exposed. The ability to texture or pattern both thefront face and the adjacent side is esthetically desirable. Such a blockmay be used along with the angled blocks to form a retaining wall havinga 90 degree corner as shown in FIG. 12. Rectangular corner block 72shown in FIG. 12 has a front face 12 having a pattern imparted byimpression face liner 70 and a second side surface 22 adjacent to frontface 12 having a pattern imparted by the compression head. A mold boxsuch as shown in FIG. 3A having mold cavities which are configured toform both corner blocks and regular wall blocks with an angled sidesurface is useful since it requires only one mold box and one mold cycleto produce both types of blocks. It should be understood, however, thatmold box 50 may be configured so that corner blocks 72 are formed in oneor more mold cavities at any desired location of the mold box. Further,it is possible to configure the mold box so that all of the moldcavities are used to form corner blocks or that all of the mold cavitiesare used to form regular wall blocks or any desired combination thereof.The illustration of the corner blocks being formed in the two moldcavities in the upper left of FIG. 3A is merely one example of how themold box may be configured.

FIG. 5A shows a mold box which is larger than mold box 50 and which has40 mold cavities. Such a mold box is designed for use on a largerproduction pallet which may have a size of 44 inches by 55 inches.Except for the size the general features of mold box 100 are similar tothose of mold box 50. Specifically, mold box 100 is configured and sizedfor use with a large production pallet which may have a size of 44inches by 55 inches.

Mold box 100 generally includes first and second mold sections 106 and108. Each mold section 106, 108 has two rows of mold cavities with 10mold cavities per row. The mold cavities are defined in each moldsection between side frame walls, and end frame walls and divisionliners in similar manner to mold box 50. As shown in FIG. 6 the moldsections can be of different size to create blocks having a width of 12inches as shown to the left or 8 inches as shown to the right.Typically, all of the blocks formed in a mold box will be of the samewidth. Each of the mold cavities have a vertical flange forming channel134 extending from the top of the mold box to the bottom and which forma flange 24 on each block. The optional cores are formed with core barswhich span the side frame walls and are used to support core forms whichcreate vertical voids in the blocks produced in the mold cavities. Thisis done in accordance with known techniques and the core bars and coreforms are not shown in the drawing. The cores may be slightly taperedinwardly from the top of the mold to the bottom to insure that theblocks may be discharged from the mold cavity without difficulty at theend of the production cycle.

Each mold section of mold box 100 includes moveable side linermechanisms 168 which are attached to impression face liners 170.Although only one side liner mechanism and face liner are shown for eachrow of mold cavities it should be understood that there may be one foreach mold cavity. The side liner mechanisms closest to the interior ofthe mold are positioned in a channel 110 located between the moldsections. During the block production cycle the movable side linermechanisms are positioned in a first inward or block forming positionwhen the mold cavities are filled with moldable material. The impressionface liners 170 may be created with any desired three dimensionaltexture or pattern and impart to the front face 12 of the retaining wallblocks any desired three dimensional texture or pattern when in thisfirst position. When the blocks have been formed and are ready to bedischarged from the mold cavities moveable side liner mechanisms 168 aremoved to a second retracted or discharge position. In this retractedposition the impression face liners are spaced from the front face ofthe blocks far enough to allow the blocks to be discharged from the moldcavities without interference from the face liners. FIG. 5B shows analternate embodiment of the mold box of FIG. 5A which does not includemovable side liner mechanisms. It should be understood that the mold boxis not limiting and variations and alternate embodiments may be used asdesired such as those described with respect to FIGS. 3A and 3B. Forexample, either blocks 10 and/or blocks 72 can be formed in anycombination in the mold cavities of mold box 100.

FIG. 6 is an end view of blocks 10 resting on a production pallet 104after the blocks have been discharged from mold box 100.

The retaining wall blocks of the present invention are made according toa process which is similar regardless of whether mold box 50 or mold box100 is used. A pallet is positioned beneath the mold to close the bottomof the mold cavity. Moldable material which may comprise dry castconcrete is then loaded from a hopper into the mold cavities through theopen top of the cavity. The moldable material in the cavity is nextcompacted by vibrating the cavity at the same time that the material iscompacted by lowering the compression head from above the open top ofthe mold cavity. The combination of the actions of vibration andcompression insure that the moldable material completely fills the moldcavity including the vertical channel in the side wall of the moldcavity which forms the flange 24 of the blocks. When sufficientvibration and compaction have been applied to insure that there are nounfilled cavities or voids within the mold cavities the blocks are readyto be discharged from the mold cavity. Prior to such discharge themoveable side liner mechanisms are retracted. Both the compression headand the production pallet are then lowered to assist in stripping theblock from the mold cavity. The compression head is then raised upwardlyout of the mold cavity and after any appropriate cleaning the productioncycle is ready to be repeated.

FIG. 7 shows multiple units of retaining wall blocks of the presentinvention stacked on a wooden shipping pallet 150. As can be seenmultiple production cycles of the blocks can be removed from theproduction pallets on which they are formed in the orientation asdepicted in FIG. 4 and stacked in multiple layers on shipping pallet150. FIG. 7 shows three layers of blocks with 60 blocks per layer for atotal of 180 blocks on the pallet. Since the blocks are placed on theshipping pallet with the angled second side up inserts 152 which mayhave a wedge or triangular shape are placed between layers in order toform a flat surface on which each succeeding layer may be placed.Inserts 152 may be made of wood, plastic, Styrofoam, cardboard or anyother material which will resist deformation in this application.

FIGS. 8, 9 and 10 are partial views of retaining walls constructed withthe retaining wall blocks 10 of the present invention. FIG. 8 shows afirst course of blocks formed in a concave curve. One block in an uppercourse of the wall is shown in crosshatch to illustrate how the rear lipor flange of the upper course connects to the back top edge of blocks inthe lower course to provide both a setback of the blocks in the uppercourse and a means of securing the upper course to the lower course. Theblocks are shown in forming a wall having a radius of approximately 3foot 4 inches. In FIG. 9 the blocks of the present invention are used toconstruct a portion of a convex retaining wall. One block in the uppercourse shown in crosshatch is illustrated to show how the rear lip orflange of the block in the upper course connects to the back top edge ofthe top surface in blocks of the lower course. If blocks having a widthof 12 inches and an angle α of 15 degrees are used to form the wall ofFIG. 9, the wall can be constructed with a radius of 3 foot 4 incheswithout any gaps between the side surfaces of blocks of the courses.FIG. 10 shows construction of a portion of a retaining wall having astraight section and a curved section.

FIG. 11 is a side sectional view of a retaining wall formed with blocksaccording to a further embodiment of the present invention. Blocks 200are similar to blocks 10 except a flange receiving channel 202 is formedinto the rear portion of the top surface and the upper portion of theback face. As shown, the flange receiving channel of blocks in lowercourses in the wall receives a portion of a flange from a block in anupper course. This configuration allows the flanges of the blocks to bemade wider without increasing the amount of setback between courses ofblocks in the wall. Blocks 200 may be formed in a mold box similar tomold box 50 or mold box 100 in which the mold cavities have beenmodified to include a vertically extending channel forming surface fromthe top of the mold cavity to the bottom of the mold cavity positionedopposite the vertical flange forming channel.

FIG. 11 also shows different core configurations which may be formedinto blocks 200. It should be understood that the same coreconfigurations and other alternatives thereto could be formed in any ofthe blocks disclosed herein. For example, the core may comprise a singlerectangular void as shown in the top block of the wall of FIG. 11.Alternatively, the core may comprise two rectangular voids separated bya vertical support web as shown in the next lower course of blocks. Afurther alternative is three round cores divided by vertical supportwebs as shown in the next lower course of blocks. The provision of coresin the blocks is advantageous for a number of reasons. First, lessmaterial is used in forming the blocks making them less costly toproduce. Second, the blocks which are formed are lighter than blockswithout cores. This is advantageous since it makes the blocks easier tohandle both in the production and shipping stages and also whenretaining walls are constructed using the blocks. Third, walls formedfrom blocks having horizontally extending cores between side surfacesmay be reinforced with horizontal reinforcement members such as rods orrebar. As the wall is constructed the cores in each block of a course ofblocks align horizontally to form a horizontal conduit or pathway sizedto accept reinforcement members of a desired length. Such horizontalreinforcement increases the strength and stability of the wall.

FIG. 12 shows a portion of a retaining wall formed with blocks of thepresent invention. The wall includes rectangular corner blocks 72 havinga textured surface formed on both the front face of the block and one ofthe adjacent side walls and wall blocks 10 having an angled sidesurface. Depending on the application and the size of the blocks beingused in the formation of the wall an optional score line may beimprinted on the top or bottom surface of the corner block during themolding process to allow the corner block to be split and create twocorner forming units which can be placed in an L-shaped formation at thecorner. Although not shown, this L-shape formation is beneficial to helpmaintain the blocks in a running bond pattern between the blocks of alower course and blocks of an upper course

Although particular embodiments have been disclosed herein in detail,this has been done for purposes of illustration only, and is notintended to be limiting with respect to the scope of the claims. Inparticular, it is contemplated that various substitutions, alterations,and modifications may be made to the invention without departing fromthe spirit and scope of the invention as defined by the claims. Forinstance, the choice of materials or variations in the shape or anglesat which some of the surfaces intersect are believed to be a matter ofroutine for a person of ordinary skill in the art with knowledge of theembodiments disclosed herein.

1. A retaining wall block for use in making a retaining wall comprising:opposed front and rear faces; opposed and substantially parallel top andbottom surfaces; opposed first and second side surfaces, the first sidesurface being orthogonal to the front and rear faces, the second sidesurface converging inwardly from the front to the rear face; a flangeextending from the rear face of the block downward past the bottomsurface of the block, the flange being configured such that the flangesof blocks in a first course of the retaining wall overlap the topsurfaces of blocks in an adjacent lower course of the retaining wall tothereby provide a connection between the courses of blocks and setbackbetween the courses of blocks in the retaining wall; and a coreextending between the first and second side surfaces, the core beingsubstantially parallel to the front and rear faces.
 2. The retainingwall block of claim 1 wherein the front face is imparted with a threedimensional surface texture or pattern.
 3. The retaining wall block ofclaim 1 wherein the core comprises a plurality of cores.
 4. Theretaining wall block of claim 1 wherein the core has a shape selectedfrom round, oval, rectangular, and square.
 5. The retaining wall blockof claim 1 wherein the second side surface forms an angle α with respectto the front face and wherein angle α is between about 5° to 20°.
 6. Theretaining wall block of claim 5 wherein angle α is between about 7½° to15°.
 7. The retaining wall block of claim 1 further comprising a channelformed into a rear portion of the top surface and an upper portion ofthe rear face, the channel extending from the first side surface to thesecond side surface.
 8. A mold assembly for use in producing retainingwall blocks comprising: a horizontal planar bottom member; a compressionhead; a mold box having a plurality of side walls that define aplurality of mold cavities having open mold cavity tops and open moldcavity bottoms, the horizontal planar member enclosing the open moldcavity bottoms of the plurality of mold cavities and the compressionhead enclosing the open mold cavity tops of the plurality of moldcavities during a block forming process, each of the plurality of moldcavities being shaped to form a single retaining wall block, eachretaining wall block having opposed front and rear faces, opposed andsubstantially parallel top and bottom surfaces, and opposed first andsecond side surfaces, each of the plurality of mold cavities beingoriented such that the first side surface is formed at the bottom of themold cavity and the second side surface is formed at the top of the moldcavity, one of the side walls of each of the plurality of mold cavitiesbeing moveable from an inward block forming position to a retracteddischarge position, the moveable sidewall having a three dimensionalsurface texture or pattern that imparts to the front face of theretaining wall block the three dimensional surface texture or patternduring the block forming process, the sidewalls of each of the pluralityof mold cavities being shaped to form a vertically extending flangeforming channel that provides the retaining wall block with a flangeextending from the rear face downward past the bottom surface of theretaining wall block; and a core forming member which extends verticallyinto at least one of the plurality of mold cavities to provide theretaining wall block formed therein with a core extending from the firstside surface to the second side surface.
 9. The mold assembly of claim 8wherein the core forming member is configured to form a plurality ofcores extending from the first side surface to the second side surfaceof the retaining wall block.
 10. The mold assembly of claim 8 whereinthe core forming member is configured to form a core having a shapeselected from round, oval, rectangular and square.
 11. The mold assemblyof claim 8 wherein the compression head includes a lower surface whichencloses the open mold cavity tops, the lower surface being angled at anangle α with respect to horizontal such that the second side surface ofthe retaining wall block formed in each of the plurality of moldcavities during the block forming process forms angle α with respect tothe front face of the retaining wall block, and wherein angle α isbetween about 5° to 20°.
 12. The mold assembly of claim 11 wherein angleα is between about 7½° to 15°.
 13. The mold assembly of claim 8 whereinthe sidewalls of each of the plurality of mold cavities are shaped toform a vertically extending ridge that provides the retaining wall blockwith a flange receiving channel formed into a rear portion of the topsurface and an upper portion of the rear face of the retaining wallblock.
 14. A mold assembly for use in producing retaining wall blockscomprising: a horizontal planar bottom member; a compression head; amold box having a plurality of side walls that define a plurality ofmold cavities having open mold cavity tops and open mold cavity bottoms,the horizontal planar member enclosing the open mold cavity bottoms ofthe plurality of mold cavities and the compression head enclosing theopen mold cavity tops of the plurality of mold cavities during a blockforming process, each of the plurality of mold cavities being shaped toform a single retaining wall block, each retaining wall block havingopposed front and rear faces, opposed and substantially parallel top andbottom surfaces, and opposed first and second side surfaces, each of theplurality of mold cavities being oriented such that the first sidesurface is formed at the bottom of the mold cavity and the second sidesurface is formed at the top of the mold cavity, one of the side wallsof each of the plurality of mold cavities being moveable from an inwardblock forming position to a retracted discharge position, the moveablesidewall having a three dimensional surface texture or pattern thatimparts to the front face of the retaining wall block the threedimensional surface texture or pattern during the block forming process,the sidewalls of each of the plurality of mold cavities being shaped toform a vertically extending flange forming channel that provides theretaining wall block with a flange extending from the rear face downwardpast the bottom surface of the retaining wall block, the compressionhead having a lower horizontal surface which encloses the open moldcavity top of at least one mold cavity, the lower surface having a threedimensional surface texture or pattern that imparts to the secondsidewall of the retaining wall block formed in the at least one moldcavity a three dimensional surface texture or pattern during the blockforming process.
 15. The mold assembly of claim 14 wherein the sidewallsof each of the plurality of mold cavities are shaped to form avertically extending ridge that provides the retaining wall block with aflange receiving channel formed into a rear portion of the top surfaceand an upper portion of the rear face of the retaining wall block.
 16. Amold assembly for use in producing retaining wall blocks of a first typeand wall blocks of a second type comprising: a horizontal planar bottommember; a compression head; a mold box having a plurality of side wallsthat define a plurality of mold cavities having open mold cavity topsand open mold cavity bottoms, at least one of the plurality of moldcavities being configured to form the first type block and the remainderof the mold cavities being configured to form the second type block, thehorizontal planar member enclosing the open mold cavity bottoms of theplurality of mold cavities and the compression head having one or morehorizontal surfaces for enclosing the open mold cavity top of the atleast one mold cavity configured to form the first type block and thecompression head having one or more angled surfaces for enclosing theopen mold tops of the remainder of the plurality of mold cavities usedto form the second type block during a block forming process, each ofthe plurality of mold cavities being shaped to form a single retainingwall block, each of the first and second block types having opposedfront and rear faces, opposed and substantially parallel top and bottomsurfaces, and opposed first and second side surfaces, each of theplurality of mold cavities being oriented such that the first sidesurface is formed at the bottom of the mold cavity and the second sidesurface is formed at the top of the mold cavity, one of the side wallsof each of the plurality of mold cavities being moveable from an inwardblock forming position to a retracted discharge position, the moveablesidewall having a three dimensional surface texture or pattern thatimparts to the front face of the retaining wall block the threedimensional surface texture or pattern during the block forming process,the sidewalls of each of the plurality of mold cavities being shaped toform a vertically extending flange forming channel that provides theretaining wall block with a flange extending from the rear face downwardpast the bottom surface of the retaining wall block; and a core formingmember which extends vertically into each of the remainder of theplurality of mold cavities used to form the second type block to providethe second type block formed therein with a core extending from thefirst side surface to the second side surface.
 17. The mold assembly ofclaim 16 wherein the one or more horizontal surfaces of the compressionhead have a three dimensional surface texture or pattern that imparts tothe second sidewall of the first type block a three dimensional surfacetexture or pattern during the block forming process.
 18. A method ofmaking a plurality of retaining wall blocks comprising: providing a moldassembly including a pallet, a compression head, a mold box having aplurality of side walls that define a plurality of mold cavities havingopen mold cavity tops and open mold cavity bottoms, and a core formingmember that extends vertically into each of the plurality of moldcavities from the mold cavity top to the mold cavity bottom, each of theplurality of mold cavities being shaped to form a single retaining wallblock, each retaining wall block having opposed front and rear faces,opposed and substantially parallel top and bottom surfaces, a flangeextending from the rear face downward past the bottom surface, opposedfirst and second side surfaces and a core that extends between the firstand second side surfaces, each of the plurality of mold cavities beingoriented such that the first side surface is formed at the bottom of themold cavity and the second side surface is formed at the top of the moldcavity, the sidewalls of each of the plurality of mold cavities beingshaped to form a vertically extending flange forming channel, one of theside walls of each of the plurality of mold cavities being moveable froman inward block forming position to a retracted discharge position, themoveable side walls having a three dimensional surface texture orpattern; positioning the pallet beneath the mold box to enclose the moldcavity bottoms; filling the mold cavities with dry cast concrete whilethe moveable side walls are in the inward block forming position;lowering the compression head to enclose the open mold cavity tops andcompress the dry cast concrete within the plurality of mold cavities;moving the moveable side walls from the inward block forming position tothe retracted discharge position; and lowering the pallet and thecompression head to strip the dry cast concrete from the plurality ofmold cavities.
 19. The method of claim 18 wherein the core formingmember is configured to form a plurality of cores extending from thefirst side surface to the second side surface of the retaining wallblock.
 20. The method of claim 18 wherein the core forming member isconfigured to form a core having a shape selected from round, oval,rectangular and square.
 21. The method of claim 18 wherein thecompression head includes a lower surface which encloses the open moldcavity tops, the lower surface being angled at an angle α with respectto horizontal such that the second side surface of the retaining wallblock formed in each of the plurality of mold cavities during the blockforming process forms angle α with respect to the front face of theretaining wall block, and wherein angle α is between about 5° to 20°.22. The method of claim 21 wherein angle α is between about 7½° to 15°.23. The method of claim 18 wherein the sidewalls of each of theplurality of mold cavities are shaped to form a vertically extendingridge that provides the retaining wall block with a flange receivingchannel formed into a rear portion of the top surface and an upperportion of the rear face of the retaining wall block.
 24. A retainingwall comprising a plurality of courses of retaining wall blocksincluding a first upper course and a second lower course, each retainingwall block having opposed front and rear faces, opposed andsubstantially parallel top and bottom surfaces, a flange extending fromthe rear face downward past the bottom surface, opposed first and secondside surfaces and a core that extends between the first and second sidesurfaces, the blocks in the first upper course being positioned overadjacent blocks in the second lower course such that the flanges of theblocks in the first course extend downward behind the top surface ofblocks in the second course to engage the rear face of blocks in thefirst course and to provide a setback from the second course to thefirst course equal to a depth of the flanges and such that the cores ofthe blocks in each course align horizontally, the cores being sized toaccept a horizontal reinforcement member.
 25. The retaining wall ofclaim 24 wherein the front face of each retaining wall block is impartedwith a three dimensional surface texture or pattern.
 26. The retainingwall of claim 24 wherein the core of each of the plurality of retainingwall blocks comprises a plurality of cores.
 27. The retaining wall ofclaim 24 wherein the core has a shape selected from round, oval,rectangular, and square.
 28. The retaining wall of claim 24 wherein thesecond side surface of each of the plurality of retaining wall blocksforms an angle α with respect to the front face and wherein angle α isbetween about 5° to 20°.
 29. The retaining wall of claim 28 whereinangle α is between about 7½° to 15°.
 30. The retaining wall of claim 24wherein the plurality of retaining wall blocks further comprise achannel formed into a rear portion of the top surface and an upperportion of the rear face, the channel extending from the first sidesurface to the second side surface.